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Engineered airflow measurement from Air Monitor gives operators accurate, repeatable, and defensible flow data while reducing the maintenance burden on CEMS technicians and facility staff. By pairing proven differential pressure technologies with application-specific design, Air Monitor helps plants keep CEMS data available, accurate, and easy to integrate into existing control and reporting architectures.

The Hidden Cost of CEMS Maintenance and Compliance Drift

Many plants still rely on basic velocity probes, aging flow sensors, or generic instruments that were not engineered for stack and duct CEMS applications. These devices often suffer from fouling, pulsating flow, poor profile coverage, or drift. These issues can appear as unexplained changes in reported emissions. The result is a steady increase in calibration checks, troubleshooting time, inaccuracy, and manual data review to ensure compliance.

Compliance drift can be subtle. A small bias in stack flow may combine with analyzer drift. Over time, reported emissions can move away from true values. In a regulatory audit or performance test, that drift becomes a serious risk, forcing plants into emergency maintenance, re-testing, over-reporting, or even derates to stay within permit limits. A properly engineered CEMS airflow system minimizes these issues from the start, so accuracy is built in rather than maintained through constant intervention.

How do Engineered CEMS Airflow Systems Work?

Air Monitor’s approach to CEMS airflow measurement starts with the flow physics in each stack or duct rather than a one-size-fits-all sensor. For general airflow monitoring, Pitot averaging flow meters sample multiple points across the duct. This provides a better view of the velocity profile under real operating conditions. Where needed, differential pressure technologies create stable, repeatable signals. They also support measurement in challenging locations.

These engineered systems integrate the primary flow element, mass flow transmitters, and automated cleaning systems into a complete solution for mass flow measurement. Automated cleaning (purge) systems ensure the flow elements remain free and clear of contaminants that can affect system performance and CEMS confidence. Together, these components provide a reliable signal to the CEMS, reducing the likelihood of sudden data dropouts or unexplained excursions in emissions reporting.

Reducing CEMS Maintenance and DCS Integration Headaches

Every CEMS group knows that time spent troubleshooting flow signals is time not spent improving reliability or supporting outages.  Engineered airflow measurement systems reduce maintenance. They use robust sensing technologies with no moving parts. They also use purge options and materials suited to the flue gas environment. Multiple sensing points properly average the flow profile. This reduces the impact of localized fouling and changing flow conditions. It also supports stable, accurate measurement across the operating range.   Another important factor is the sensor’s ability to compensate for angular flow components.  These velocity vectors that are not following the main axis of the stack can be significant when stacks are fed tangentially at the base resulting in cyclonic flow.

Engineered airflow measurement systems simplify DCS integration with clear signal scaling, comprehensive documentation, built-in diagnostics, and a properly averaged flow profile. Rather than managing multiple individual probe signals and associated uncertainties, operators receive a single, accurate measurement output that is straightforward to configure, validate, and interpret. This approach improves measurement reliability, reduces integration complexity and commissioning time, and minimizes the potential for errors during new installations and retrofit projects. The result is faster commissioning, fewer integration errors, and more dependable data for process control and emissions reporting throughout the life of the installation.

Improving Emissions Monitoring Accuracy and Plant Operating Costs

Accurate, stable stack flow measurement is the foundation of reliable emissions reporting. Trustworthy airflow data helps engineers evaluate emissions trends. It also helps them verify process changes and avoid decisions based on bad data. This provides a clearer understanding of actual plant performance and reduces the uncertainty that can complicate compliance reporting. The result is greater confidence in environmental performance, more accurate reporting, and stronger support for regulatory compliance. Lower CEMS maintenance hours reduce operating costs. This translates to fewer re-tests, more uptime, and fewer over-reported emissions. Engineered airflow systems deliver value over their lifetime by reducing failure-related callouts and limiting the need for emergency replacements during critical operating periods. For plants under tight margins, these savings help justify better CEMS hardware. The payback comes from less troubleshooting, fewer nuisance alarms, more accurate reporting, and smoother audits.

Where Air Monitor Fits in Your CEMS Strategy

Air Monitor has focused exclusively on airflow measurement since 1967, supplying solutions to commercial HVAC, industrial process, and power generation customers. With expertise in differential pressure and Pitot averaging technologies, Air Monitor can match the right airflow technology to each application instead of forcing a single design into every stack or duct. This flexibility is especially important for plants with multiple stacks, uncommon ducts, complex layouts, or corrosive gases, where one airflow approach may not fit every location.

For CEMS applications, Air Monitor’s Pitot averaging and differential pressure flow systems can be tailored to the duct geometry, temperature range, gas composition, and regulatory requirements of each site. Combined with automated purge systems, plants can build a near maintenance-free airflow solution that supports both process control and accurate emissions monitoring. The result is a CEMS airflow system that aligns with plant goals for accuracy, reliability, and long-term maintainability.

Ready to Explore CEMS Options?

If you are planning a CEMS upgrade, facing recurring maintenance issues, or preparing for a regulatory audit, now is the time to reassess your airflow measurement strategy. Request an application review to evaluate stack geometry, operating conditions, signal requirements, and CEMS integration needs. Partnering with a dedicated airflow solutions provider can help you protect compliance, control operating costs, avoid over-reporting emissions and gain confidence in your CEMS data over the long term.

Additional Resources:

• View our Continuous Emissions Monitoring Systems product line.

Air Monitor has been delivering engineered airflow measurement solutions since 1967. As the premier solutions provider for Commercial HVAC, Industrial Process, and Power Generation markets, Air Monitor offers both differential pressure and thermal dispersion measurement technologies — because the right technology for the right application is never one-size-fits-all. Learn more at airmonitor.com.

Dirty Airflow: Dust and Particulate Matter Cause Havoc

In many industrial processes, dust and particulate in the airstream can wreak havoc on flow measurement devices. As sensors get clogged, operators experience forced trips, drifting signals, and gradual degradation of performance over time. The new “Air Monitor: How can you avoid maintenance issues from dirty air and particulate matter on sensors?” video illustrates this problem. It also shows how an automated purge solution changes the story. It’s designed for engineers, operators, and maintenance teams who need reliable airflow data in challenging environments.

How AUTO-purge Keeps Sensors Clean

Instead of waiting for signal drift to hint that something is wrong, the AUTO-purge system proactively gets to work. It cleans the sensing ports on a programmed schedule tailored to your process conditions. Short bursts of high-pressure air clear dust and particulate from the measurement station. Meanwhile, the system holds the process signal, so you maintain continuous, trustworthy flow data. This automated approach supports Air Monitor’s Pitot-averaging and differential pressure flow technologies in dirty, particulate-laden applications. Automating this function is especially useful in processes where manual cleaning is difficult or costly.

Benefits for your Facility

By keeping sensors clean without frequent manual intervention, AUTO-purge helps reduce maintenance labor, minimize exposure to harsh environments, and cut unplanned downtime related to fouled flow elements. The result is more reliable and accurate airflow measurement, better process control, and improved confidence in your data for compliance and performance monitoring. As the leader in precision airflow measurement, Air Monitor offers purge solutions engineered specifically for dirty-air industrial processes.

Watch the Video and Learn More

You can watch the new animated video on YouTube here.

To dive deeper into particulate-laden airflow solutions and AUTO-purge options for your facility, explore our purge systems and dirty-air application resources at the button below. Our team can help you match the right airflow measurement and purge technology to your specific process conditions.

Many coal, gas, and oil‑fired units now sit at low load for long periods waiting to ramp for peak demand. This circumstance makes accurate, repeatable airflow measurement over a broad turndown range more important than ever.

Common pain points with traditional secondary airflow measurement

In the new Secondary Airflow in Power Plants Application Guide, Air Monitor outlines the practical challenges many plants face. Legacy devices like airfoils, venturis, and thermal flow meters often lead to troublesome issues like:

• Accuracy and signal stability often collapse at reduced boiler loads. This is exactly when reliable airflow data is most critical for safe combustion control.
• Limited straight duct runs create highly distorted, non‑uniform flow profiles that conventional devices struggle to average accurately.
• Fouling from fly ash and other particulates drives frequent maintenance and can quietly degrade measurement accuracy between cleanings.
• High permanent pressure loss from traditional elements wastes fan power and can reduce available boiler capacity.

Thus operators face difficulties to run tighter air‑to‑fuel ratios, improve NOx/SOx performance, and still protect the furnace from unsafe conditions.

How Air Monitor’s multipoint solutions address these challenges

Air Monitor’s multipoint Pitot probe arrays and combustion airflow stations are engineered specifically for large secondary air ducts and distorted flow profiles. They perform well even in the challenging dirty process conditions found in utility boiler service. Key advantages include:

• High turndown accuracy — VOLU‑probe and CA Station arrays, paired with the CAMS™ Combustion Airflow Management System are recommended. They deliver stable, repeatable airflow measurement over turndown ratios of 10:1, supporting precise control even at minimum load.
• Performance without long straight runs — High‑density sensing points and proprietary compensation for pitch, yaw, and profile asymmetry allow accurate airflow averaging. Common installation points are downstream of air heaters, elbows, and multiple‑fan arrangements where straight‑run requirements simply cannot be met.
• Lower maintenance in dirty service — Integrated AUTO‑purge (self‑cleaning feature) keeps sensing ports clear of fly ash and particulates. This feature helps plants maintain accuracy and reduce manual cleaning intervals.
• Minimal pressure loss — Multipoint Pitot solutions introduce negligible permanent pressure drop compared to venturis and airfoils, helping preserve fan capacity and reduce fan power consumption.

What you’ll find in the new Application Guide

The information in this Application Guide is helpful for engineers, plant operators, and maintenance teams responsible for combustion performance. In this guide you’ll find:

• Clear explanation of why secondary airflow is foundational for modern combustion control strategies.
• Concise overview of the most common measurement challenges seen in real‑world plants.
• Practical description of how Air Monitor’s engineered systems can be applied. This includes typical locations and configurations in secondary air ducts of a utility boiler system.

For readers already familiar with Air Monitor’s broader industrial offerings, this guide complements the Secondary Airflow content in the Industrial Airflow Applications section of airmonitor.com.

To see how plants like yours can improve combustion efficiency, reduce emissions, and cut fan energy with reliable secondary airflow data, download the new Secondary Airflow in Power Plants Application Guide today. For a deeper discussion of your specific duct layout, load profile, and regulatory goals, connect with an Air Monitor applications engineer through the Industrial section of airmonitor.com.

Air Monitor has been delivering engineered airflow measurement solutions since 1967. As the premier solutions provider for Commercial HVAC, Industrial Process, and Power Generation markets, Air Monitor offers both differential pressure and thermal dispersion measurement technologies — because the right technology for the right application is never one-size-fits-all. Learn more at airmonitor.com.

The High Stakes of Data Center Cooling

Modern data centers are power-hungry environments where cooling can represent 30–40% of total power consumption. High-density server racks can demand as much as 60 kW of power per rack — ten or more times the heat per square foot compared to older configurations. Without proactive airflow monitoring, heat builds into hotspots, triggering equipment failures, unplanned downtime, and costly repairs.

The consequences of poor airflow management cascade quickly: overheating degrades hardware, cause cooling systems to run in overdrive, and can slash equipment lifespan significantly. Effective airflow monitoring keeps those risks in check by delivering real-time data that drives smarter, faster operational decisions.

Are There Regulations to Address During Construction?

Yes — and engineers should plan for them from day one. The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) is the primary standards body governing data center environmental design. ASHRAE Standard 90.4, published in 2016 and regularly updated, establishes minimum energy efficiency requirements for data center design, construction methods, and HVAC systems.

ASHRAE 90.4 is not just advisory — it carries regulatory weight. The 2021 and 2024 International Energy Conservation Code (IECC) (Section C403.1.2) requires compliance with Sections 6 and 8 of ASHRAE 90.4, covering HVAC and electrical systems. States including Virginia and Washington have incorporated ASHRAE 90.4 directly into their energy codes, making compliance legally mandatory for data center construction in those jurisdictions.

For environmental conditions specifically, ASHRAE guidelines set the recommended operating envelope for Class A1–A4 data centers at 18°C to 27°C (64°F–80°F), with relative humidity and dew point controls to prevent condensation and static discharge risks. The standard also references ASHRAE 52.2 for air filtration requirements, recommending at minimum MERV 8 filters that trap 70% of particles 3.0 microns and larger. Facilities that fail to meet these thresholds during construction risk costly retrofits, code violations, and reduced equipment reliability from day one.

The Most Important Aspect of Airflow Control: Hot/Cold Air Separation

If there is one principle at the core of data center airflow management, it is this: keep hot exhaust air and cold supply air completely separated. When these two airstreams mix, cooling systems must work significantly harder — a data center without proper airflow management (AFM) may require up to four times the cooling capacity to handle the same thermal load as a facility with disciplined separation.

The industry standard approach is the hot aisle/cold aisle (HACA) configuration, where server racks are positioned front-to-front and back-to-back. Cold supply air flows into server intakes from the cold aisle; hot exhaust exits into the hot aisle and routes directly back to cooling units. Physical containment systems — either Hot Aisle Containment (HAC) or Cold Aisle Containment (CAC) — enclose each respective aisle to eliminate air mixing.

But layout alone is not enough. Ongoing pressure differential monitoring between hot and cold aisles is critical to verifying that containment is working as designed. Even small leaks — such as unsealed cable cutouts — can reduce airflow efficiency by up to 30%. This is where precision instrumentation becomes indispensable.

Precision Measurement: The Role of Airflow Instrumentation

Accurate, real-time data is what separates a well-managed data center from one running on assumptions. Differential pressure measurement technology is particularly well-suited for data center aisle pressurization monitoring — it captures the precise pressure differential between hot and cold aisles to confirm airflow is flowing in the right direction and at the right volume.

 Transmission of Flow and Pressure Data

Air Monitor offers two advanced solutions for differential pressure measurement in data centers: the VELTRON II and DCAS (Data Center Aisle Sentry). Both are purpose-built to deliver accurate, reliable performance at the ultra-low pressure levels required for effective airflow and containment control.

The VELTRON II is the premium option, delivering ultra-high 0.1% accuracy along with integrated AUTO-zero circuitry to maintain long-term stability. With an industry-leading 100:1 turndown ratio, it’s an ideal no-compromise solution for applications where precise, continuous measurement is critical.

The DCAS provides a cost-effective alternative without sacrificing performance. Its dual-channel design achieves ±0.75% of reading accuracy over a 40:1 turndown—well beyond the capabilities of conventional transmitters that tend to lose accuracy near zero.

Sensors for Flow and Pressure

Each device is used in conjunction with Air Monitor’s SAP (Static Air Pressure) sensors, which ensure accurate pressure sensing directly at the measurement location. Together, these components form a complete, high-performance solution for data center pressure control.

For facilities aiming to maintain tight control at low differential pressures, this level of accuracy can translate into meaningful gains in energy efficiency, improved thermal stability, and operational savings.

 For facilities requiring bulk airflow monitoring across supply ducts and air handling units, Air Monitor offers proven solutions such as the FAN‑Evaluator and VOLU‑probe. These Pitot averaging flow meters use differential pressure principles to provide reliable, cost-effective measurement across large duct cross-sections.

Unlike single-point and low sensor density systems, Air Monitor’s multi-point Pitot averaging technology captures true airflow velocity across the entire duct profile—delivering far greater measurement accuracy and repeatability in dynamic operating conditions. When paired with high-performance differential pressure transmitters like the VELTRON II, these systems provide a fully integrated approach delivering the level of measurement integrity required in mission-critical data center environments.

Ready to optimize your data center’s airflow monitoring?

Explore Air Monitor’s data center solutions at airmonitor.com to see how precision differential pressure measurement can reduce energy costs and protect uptime.

Air Monitor has been delivering engineered airflow measurement solutions since 1967. As the premier solutions provider for Commercial HVAC, Industrial Process, and Power Generation markets, Air Monitor offers both differential pressure and thermal dispersion measurement technologies — because the right technology for the right application is never one-size-fits-all. Learn more at airmonitor.com.

Why Accuracy Really Matters

Plant standard transmitters struggle with issues like limited flow turndown, temperature effects, and zero and span drift. Over time, these issues can stack up. Errors in flow data make it harder to keep processes stable, protect workers, and stay within emissions targets.

These common error sources show up in everyday operation and traditional “one-size-fits-all” transmitters often fall short of need. This is especially true in ultra-low flow or highly dynamic applications.

How Air Monitor Transmitters Improve Real-world Performance

Air Monitor transmitters are designed with a selection of upper range limits (URLs). This allows for a close match of the calibrated span to the actual operating range instead of wasting resolution on unused capacity. This tighter fit allows for usable accuracy where it counts—within your real process conditions.

The video highlights how Air Monitor transmitters are calibrated and configured for each specific application. The benefit of which is felt most in challenging ultra-low differential pressures and variable flows. Combined with the AUTO-zero function that electronically compensates for drift and keeps the transmitter operating within a small fraction of its span, users get more stable, “self-correcting” airflow measurements over time.

See the AUTO-zero Advantage

AUTO-zero continuously fights the zero drift that can creep into any pressure-based measurement from thermal, mechanical, and electronic influences. By automatically re-zeroing the transmitter at set intervals while holding the output, the function maintains accuracy without interrupting control or requiring frequent manual intervention.

The animation shows how this capability pays off in real applications—helping operators maintain tighter control, reduce nuisance tuning, and trust the data driving critical decisions.

Watch the Video and Learn More

If you’re responsible for process control, plant safety, or environmental performance, this short, animated video is a fast way to understand what truly separates a plant standard transmitter from a high-accuracy airflow measurement solution.

Watch now: What makes an airflow measurement transmitter more accurate?

To explore Air Monitor’s full lineup of airflow measurement transmitters and engineered solutions, visit our Transmitter Product below.

When Air Monitor’s pitot averaging flow stations are paired with the AUTO-purge III system, they create a comprehensive, end-to-end airflow monitoring solution specifically tailored to dirty or particulate-laden environments. Here’s how the integrated system functions:

System Components

Averaging Pitot Probes/Stations: Multiple pressure sensing ports mounted at optimized locations along the probe capture dynamic and static pressure across the ductwork cross-section, automatically averaging velocity and reducing the impact of flow disturbances.

Differential Pressure Transmitter: A high-precision transmitter converts the differential pressure into an electronic signal (typically 4-20 mA or digital output) proportional to airflow velocity.

AUTO-Purge III Purge System: An intelligent control module manages purge timing, duration, and air/gas supply based on sensor configuration and facility preferences—either timed intervals or demand-based activation.

Purge Supply System: A regulated source of clean, dry compressed air or inert gas (nitrogen for safety-critical applications) feeds the purge controller.

Ductwork Installation: The averaging pitot probe or station is installed in a straight section of ductwork, upstream or downstream of a major dust-generating process where reliable airflow data is critical for process control and regulatory compliance.

Continuous Measurement Workflow

1 – Continuous Sensing: The averaging pitot station captures dynamic and static pressure continuously as air flows through the duct, automatically averaging across multiple pressure taps to yield a representative velocity measurement.

2 – Purge Cycles: At programmed intervals, the AUTO-purge III injects a sustained blowback of clean compressed air through internal sensing paths, sweeping away any particulate and moisture before they accumulate.

3 – Real-Time Airflow Calculation: The transmitter converts differential pressure into mass or volumetric airflow in real-time, accounting for temperature, pressure, and gas density if needed.

4 – System Integration: Airflow data is transmitted to facility control systems, baghouse controllers, or monitoring platforms for real-time process optimization, regulatory compliance documentation, predictive maintenance alerts, and historical data logging.

5 – Minimal Maintenance: Because AUTO-purge III keeps the probe clean, maintenance is reduced to occasional checks of purge gas supply and recalibration during planned shutdowns—far less frequent than conventional probes in dirty environments.

Real-World Applications

Cement and Concrete Plants

Measurement Points: Kiln airflow, baghouse inlet velocity, and clinker cooler inlet/outlet air.

Challenge: Cement dust is fine, sticky, and hygroscopic—it loves moisture and can adhere to sensor surfaces.

Benefit: Real-time feedback enables operators to balance baghouse cleaning cycles, adjust fan speed for minimal energy use, and document continuous compliance with NESHAP/MACT standards and regional cement emission limits. Facilities report 5–15% energy savings through optimized fan operation alone.

Materials Handling and Dust Collection

Measurement Points: Inlet and outlet airflow from multi-stage baghouse systems connected to silos, mills, and conveyor systems.

Challenge: Ultra-fine dust concentrations (often 100+ mg/m³ at baghouse inlets) overwhelm conventional sensors within days.

Benefit: AUTO-purge III keeps probes functional even in particulate-laden inlet streams. Operators quickly detect filter blinding, duct leaks, or fan failures and respond before emissions spike or production halts. Reduced unplanned downtime translates directly to improved throughput and compliance records.

Coal-Fired Power Generation

Measurement Points Primary air, secondary air, individual burner air, over-fire air, total air, flue gas to carbon capture, and stack monitoring systems.

Challenge: Coal dust is abrasive and corrosive, creating one of the challenging measurement environments in industrial process control.

Benefit: Averaging pitot technology captures true airflow despite turbulence and flow disturbances from mill discharge. AUTO-purge III prevents coal dust accumulation, enabling reliable long-term ESP (electrostatic precipitator) or baghouse monitoring for emission compliance.

Industrial Process Exhaust Monitoring

Measurement Points: Pharmaceutical, chemical, or food processing facilities with high-particulate or corrosive vapor exhaust streams routed through baghouses or scrubbers.

Benefit: Continuous airflow data supports process control and emissions compliance while AUTO-purge III tolerates sticky residues or corrosive dust that would rapidly foul conventional sensors.

Key Advantages Over Alternative Technologies

Airflow technology comparison table:

Measurement Method	Accuracy	Fouling Resistance	Maintenance Burden	Suitable for Dirty Air?
Manual Pitot + Manometer	±3–5%	Low—requires frequent cleaning	High—labor intensive	No—impractical for continuous use
Differential Pressure Gauge	±2–3% (indirect)	Medium	Medium	Partially—indirect measurement unreliable
Thermal Anemometer	±2–3%	Very Low—clogs in dust	Very High—frequent replacement	No—fails rapidly
Electronic Sensor (unprotected)	±1–2%	Very Low	Very High—weeks to failure	No—sensor fouls immediately
Pitot Averaging + AUTO-Purge III	±1–3%	Excellent—active fouling prevention	Low—proactive cleaning	Yes—engineered for harsh conditions

Return on Investment: The Numbers Behind the Solution

While initial investment in pitot averaging + AUTO-purge III exceeds basic differential pressure gauges or manual measurements, the payback comes through several channels:

Reduced Maintenance Interventions: Conventional sensors in dirty environments require probe removal, cleaning, and verification every 2–4 weeks. At $500–$1,000 per intervention (labor, production disruption), annual maintenance costs reach $13,000–$26,000. AUTO-purge III systems eliminate 80–90% of these interventions, recovering investment within 2–3 years.

Elimination of Probe Replacement: Fouled probes require calibration verification or complete replacement ($2,000–$4,000 each). Facilities implementing AUTO-purge III experience 50–75% fewer replacement cycles over 5 years, saving $15,000–$30,000.

Optimized Fan Operation: Real-time airflow data allows operators to identify and correct inefficient fan operation. Reducing fan speed by just 10% (via variable frequency drive adjustment) based on actual airflow monitoring reduces energy consumption by ~27% due to the cubic relationship between speed and power. For a 50 kW baghouse fan, this represents $5,000–$10,000 annual energy savings.

Avoided Compliance Violations: Continuous airflow documentation provides irrefutable compliance records. Facilities avoiding even one notice of violation or fine (which can reach $10,000–$50,000+) recover the entire system investment.

Reduced Unplanned Downtime: Predictive maintenance alerts allow scheduled maintenance instead of emergency repairs. Avoiding even two emergency service calls per year (at $2,000–$5,000 each) provides substantial ROI.

Typical Payback Calculation (assuming a $25,000–$35,000 installed system cost):

• Maintenance reduction: $10,000–$15,000/year
• Energy optimization: $5,000–$10,000/year
• Compliance and downtime avoidance: $5,000–$15,000/year
• Total annual savings: $20,000–$40,000
• Payback period: 1–2 years

Over a 10-year system lifespan, facilities typically realize $150,000–$300,000 in cumulative value—a return multiple of 5–10x the initial investment.

Integration with Modern Systems

Standard Communication Protocols: Transmitter outputs integrate via 4–20 mA analog signals or Modbus RTU protocols, enabling seamless connection to baghouse pulse-jet controllers, distributed control systems (DCS), facility-wide energy monitoring platforms, and remote cloud-based dashboards.

Historical Data and Trending: Continuous monitoring enables trend analysis, seasonal pattern recognition, and long-term performance benchmarking—insights impossible with episodic manual measurements.

Why Air Monitor’s Solution Stands Out

Air Monitor has been delivering airflow measurement solutions since 1967, establishing deep expertise in differential pressure technology. The company’s commitment to matching the right technology to the right application—rather than forcing a one-size-fits-all approach—shines through in the engineering of pitot averaging flow stations paired with AUTO-purge III.

Air Monitor’s approach emphasizes:

Application-Specific Design: Understanding dust characteristics, temperature profiles, and regulatory drivers unique to each facility.

Proven Reliability: Decades of field experience in cement plants, power generation, and materials handling.

Total Solution Integration: Not just selling sensors, but partnering to design ductwork layouts, specify transmitter ranges, integrate control communications, and establish maintenance protocols.

Engineered Solutions: Commitment to engineering purpose-built solutions rather than generic components.

The Path Forward

Pitot averaging flow stations with AUTO-purge III represent the engineered solution for facilities demanding reliable, accurate airflow monitoring in dirty, particulate-laden environments. By combining proven averaging pitot technology with proactive sensor protection, this system delivers unmatched accuracy, minimal maintenance burden, continuous regulatory compliance, and lower total cost of ownership.

For cement plants, power generators, materials handling facilities, and any industrial operation where accurate airflow measurement drives both safety and profitability, this solution stands as the industry standard.

Ready to optimize your airflow monitoring system?

Contact Air Monitor to discuss your specific application, facility layout, and regulatory requirements. Learn how continuous, reliable airflow measurement can transform process efficiency and regulatory compliance in your operation.

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Why Turbulent, Angular Airflow Is a Problem

In real systems, airflow is often turbulent and non-uniform, especially downstream of elbows, tees, dampers, and fans. These disturbed, angular flow profiles can significantly reduce the accuracy of many common flow measurement devices, even when their datasheets show impressive accuracy specifications. The catch is that those specifications usually assume long upstream and downstream straight runs that you may not have in your actual installation.

How Air Monitor Handles Angular Flow With Limited Straight Run

The new animation explains how you can still achieve accurate airflow measurement in angular, multidirectional flows with limited straight run when you apply the right technology. Air Monitor is the only airflow measurement device manufacturer that offers patented solutions specifically engineered for these challenging conditions. Our Fechheimer static and chamfered total pressure technology, used in our flow elements, is designed to be insensitive to approaching multidirectional airflow, so it maintains accuracy even when the velocity profile is distorted. When combined with built-in flow conditioners on our flow stations, these elements further correct the flow profile, helping recover reliable, repeatable measurements in tight layouts.

Watch the Video and Explore Turbulent Airflow Solutions

If your duct layouts do not meet traditional straight run requirements—or if you suspect angular flow is harming your measurement accuracy—this animated video is a fast, visual way to see what is possible with engineered airflow solutions. Watch the new turbulent airflow video on the Air Monitor YouTube channel, then click through the link in the video description or visit airmonitor.com to learn more about our patented solutions for turbulent, angular airflow challenges.

Air Monitor has released a new animated video, “What’s better in airflow measurement: Multi point measurement or single point measurement?”. It’s available now on our YouTube channel. In under a minute, the video breaks down how multi-point averaging technologies compare to single-point sensing when you need accurate, repeatable airflow data.

Why Multi-Point Measurement Matters

Airflow in real ducts is rarely uniform, especially near elbows, dampers, fans, or size transitions. This fact makes a single-point reading highly dependent on where you place the sensor. The video shows how Air Monitor’s multi-point averaging pitot approach samples velocity pressure at multiple locations across the duct to deliver a truer representation of total airflow.

What You’ll See in the Animation

Through simple visuals, the animation compares a single-point probe installed near an elbow. Without long straight duct runs, the single point sensor will give an erratic flow output as a result. Conversely, a multi-point averaging probe with built in flow conditioning will produce a steady flow output signal. It illustrates how multi-point measurement reduces error, improves turndown, and supports better control decisions.

Watch the Video and Learn More

If you are selecting airflow devices for a new project or troubleshooting inconsistent readings in the field, this short video is a quick way to understand when multi-point measurement is the better choice. Watch “What’s better in airflow measurement: Multi point measurement or single point measurement?” on the Air Monitor YouTube channel, and subscribe to see more application and technology-focused animations as they are released.

In many real-world ducts for industrial processes, you simply do not have the luxury of long, straight runs before and after your flow sensor. That doesn’t mean you have to settle for poor accuracy in tight spaces. Air Monitor’s new animated video shows how our engineered airflow solutions deliver reliable measurements in short duct runs.

Why Straight Run Still Matters

Flow disturbances from elbows, fittings, and fans create swirl and non-uniform velocity profiles that can lead to significant accuracy errors. If you rely on single-point sensing or basic differential pressure devices, long straight duct runs are required to maintain accuracy. In the video, see how multi-point self-averaging pitot technology and application-specific airflow stations overcome these challenges and restore confidence in your readings.

What You’ll Learn in the Video

Air Monitor’s flow stations measure flow across the duct and deliver stable, repeatable flow data — even when straight duct runs are short. This approach helps engineers and facility teams maintain proper airflow for better process performance without major ducting rework.

Watch the Video and Take the Next Step

If you’re wrestling with short duct runs, fan discharges, or crowded mechanical rooms, your device accuracy will be affected. Watch our new video at the link above, then connect with an Air Monitor application expert. Together, we’ll review your specific layout and select the right airflow measurement solution for your project.

We are excited to announce the launch of the new Air Monitor Corporation YouTube channel! This channel is dedicated to practical airflow measurement insights for commercial HVAC, industrial process, and power generation applications.

Inside the Air Monitor Factory Tour

To kick things off, our first video is live! Our brief factory tour video brings our engineered airflow solutions to life in our 42,000 sq ft facility. Notably, Air Monitor’s manufacturing team design and produce airflow probes, stations, and systems. Beyond fabrication, you’ll see wind tunnel calibration site and quality checks that support AMCA-certified accuracy. Thus, the video gives engineers, facility managers, and operators a behind-the-scenes look at the Air Monitor facility. Air Monitor products perform in challenging duct configurations, low and high velocities, clean airflow, and particulate-laden airstreams. Watch the tour here: https://www.youtube.com/watch?v=5iAhCpl0GYE.

Upcoming Animated Airflow Measurement Videos

Coming soon, this channel will feature a growing series of animated, application-focused and technology-focused videos. Topics range from ducted airflow measurement and fan inlet monitoring to combustion air, dirty air process, and building pressurization. The short explainer video series is designed to show where to apply multi-point averaging pitot technologies. In addition, you’ll see how to solve low-flow and large-duct measurement challenges, and how to get the most from your Air Monitor systems.

Subscribe to the Air Monitor YouTube Channel

Now is the perfect time to subscribe so you don’t miss upcoming videos. Visit the Air Monitor Corporation YouTube channel, watch the factory tour, and click Subscribe and the notification bell to stay up to date as we release new animated application and technology content in the weeks ahead.